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Owner's Manual: 6500 Watt Silent
Owner's Manual: 6500 Watt Silent
Owner's Manual: 6500 Watt Silent
TM
Owner’s Manual
6500 WATT SILENT
DIESEL GENERATOR
www.allpoweramerica.com
Preface
Thank you for purchasing this ALL-Power Generator. We are proud of our
products and have designed this unit for years of safe, reliable service.
This manual will instruct you in the proper operation and service of your All-Power
generator. Please read this manual prior to using the generator to insure safe and
proper operation. At all times, follow the instructions to keep your generator in the
best working condition and to extend its life. Should you have any comments or
problems, please contact us at 888-896-6881 and we will direct you to an
authorized parts and service center. Unless there was concealed damage, do not
take this unit back to the retailer where you purchased it. We will work with you to
answer any questions and solve any problems.
This manual addresses the general operation of this unit. As products and their
operation can change, this manual is intended only for use with this specific
model and does not refer to any other models offered by our company.
Please pay particular attention to the warning and caution indicators both within
this manual and on the unit itself.
The All-Power diesel generator will perform safely and to specification if operated
according to the following instructions. Failure to do so may result in serious
personal injury and/or equipment damage. If you do not understand the contents
of this instruction manual, contact All-Power America, at 626-961-5640 for
further clarification.
1
Warning:
o The muffler and engine body of this generator get very hot when the
engine is operating or shortly thereafter. Do Not Touch these parts or
you may be severely burned.
2
o Note: This generator is not waterproof and therefore should not be
placed in rain, snow, standing water or any area where there could be
water spray. Operating a unit in these environments may cause
electrical short circuits that can cause electrical shocks.
o This generator should also be grounded to prevent electrical shocks
from faulty appliances. To ground this unit, simply connect a length of
heavy copper wire between the unit and a ground source.
o Do Not plug in any power cord until after the unit is operating. If
equipment is attached when starting the generator, it may cause the
unit to move resulting in potential injury.
Caution
Most appliances require more power to start than their rated wattage.
Therefore make certain that you do not overload the generator with too
many appliances.
Do not exceed the current limit of any of the sockets on the generator.
5. Batteries:
Batteries contain sulfuric acid which can burn your eyes and skin.
Whenever working with a battery, protect your eyes and skin from
exposure to the acid. In case of contact with any acid, act immediately by
thoroughly flushing the affected area with clean cold water and seek
prompt medical attention.
Batteries also generate hydrogen gas which can be extremely explosive.
Do not smoke or allow flames near a battery, especially while in a
charging mode. Always charge batteries in a fully ventilated area.
3
Contents
2. Configurations ............................................................................2
9. Long-Term Storage................................................................. 19
4
1. Technical Specifications and Data
Model APG3202
Rated frequency (Hz) 60
Rated voltage (V) 240/120
Rated current (A) 25/50
Rated output power (kVA) 5.0
Max output power (kVA) 6.5
Rated rotation speed (rpm) 3600
Power factor cos 1
Phase number Single
Pole number 2
self-excitation constant voltage
Excitation Transistorized
(AVR)
Single cylinder,4-stroke,air-
Engine type
cooled,vertical,diesel engine
Bore stroke(mm) 86 72
1
2. Configurations
2.1 Parts name
OUTLET FOR
COOLING AIR
DC OUTPUT
AC OUTPUT
2
2.2 Control panel
3
3. Before Starting Your Generator
Warning:
Refuel in a well-ventilated area with the engine off.
Do not smoke or allow open flames or sparks near where you are
refueling or where the fuel is stored.
Do not overfill the tank. Make sure that the fuel cap is securely tightened
after refueling.
Do not spill any fuel. If fuel is spilled, make certain that the spilled fuel is
removed before starting the engine.
Warning:
Before every start, make certain that your generator is on a level surface
and then check the oil level.
The engine may be damaged if it is operated with insufficient oil.
Too much oil may cause a sudden increase in engine speed also
damaging your generator.
Caution: Your All-Power generator is equipped with a “low oil” warning system. This
system automatically stops the engine when the oil level becomes dangerously
low, preventing major damage to your generator. Do not rely totally on this
system for maintaining proper oil levels, as it only represents an emergency
situation and not a method for checking your generator’s oil level.
4
Oil Selection
It is very important that you select the proper engine oil to maintain the life and
performance of your generator. If inferior or the wrong weight oil is used, or if your
engine oil is not replaced periodically, there is a risk of major damage to your
engine due to overheating. All-Power recommends CC/CD oil only classified by API.
Choose the applicable viscosity according to your local temperature.
Caution:
Do not wash the filter with
detergent.
Replace the air filter when it
impedes the flow of air and cannot
be completely cleaned. One
indicator is when the engine
exhaust changes color.
Never operate the generator
without the air filter.
5
3.4 Checking the Generator Low oil warning lamp
Warning:
Turn off the main switch
AC output receptacle Ground terminal
before starting
The generator must be grounded
to prevent electrical shocks.
Caution:
The main switch must be in the “on”
position during operation.
Before starting the engine, either unplug the devices to be powered or
make certain that all of the devices are turned “off”. If the switches for the
devices are left in the “on” position and the generator is started the sudden
surge in power can be very dangerous.
6
3.5 How to open the cabinet door and remove the protective
covers of the generator.
The first 20 hours of operation are required to properly seat your generator’s
operating parts. During this period, the following steps must be taken:
During the initial operation, run the generator at low speed and with nothing
plugged in for a minimum of five minutes.
Avoid applying any heavy demands to the unit during the break-in period.
All-Power recommends that the engine be operated at 3,000 RPM with no more
than a 50% load for the first 20 hours of operation.
7
4. Starting the Generator
Turn the ignition key clockwise to the “START” position removing your
hand from the key as soon as the engine starts. If the engine does not
start in 10 seconds, wait 15 seconds and repeat the process.
8
2. Battery: If the battery has an open cell
design, check the water level every month.
If it is low, refill using distilled water until
the cell is full. If the battery is a sealed unit,
checks for cracks and leaks.
Caution
If the distilled water level is too low, the engine may fail to start because there
isn’t sufficient battery power. If the water level is too high, the fluid will corrode
surrounding parts shortening the life of the battery. Always maintain the level of
distilled water at the recommended level. Never use well or tap water as the
minerals in the water will destroy your battery.
Caution
The low oil warning light is activated by either a low pressure level or an
inadequate amount of oil in the reservoir. When the low oil light is activated,
9
the engine will automatically stop. If you attempt to start the generator
without addressing the problem, the unit will not start. When the “low oil”
light illuminates, check the oil level first to make certain that there is
adequate oil in the reservoir.
Do not adjust either the engine governor bolt that controls engine speed or
the fuel injection bolt that controls fuel mix. Doing so will affect the overall
performance of your generator.
Caution
Do not attempt to start two or more devices simultaneous. First plug in or
start one device and then the next and then the next.
Do not use floodlights with other devices.
6.1 AC application
Make certain that you operate the generator at its rated speed in RPM’s. If
this is not done, the AVR or Automatic Voltage Regulator will incorrectly
produce too much voltage shortening the life of the AVR.
After switching on the air switch, check the voltmeter on the control panel.
The voltmeter should point to 120V +/- 5% for a single phase generator and
230V +/- 5% (50 Hz) for a multiphase generator.
10
When the dual voltage generator exceeds or is below these levels, then the
“air” switch should be in the “OFF” position. If not both the generator and the
devices powered by it can be damaged.
Always connect devices to the generator with the highest demand device
first and then the lesser demand devices afterward. If the operation
becomes overloaded, the generator engine will lag or stop suddenly. If this
happens, unplug all devices immediately, turn off the main switch on the
generator and check all systems.
Three phase generators
Make certain that you balance all three phases during operation. Stop
the engine and check to see if the generating is operating within 20% of
specification. If the engine is not, reduce your load or turn off the
generator.
The sum of the load for each phase must be below the overall rated
load. In addition, the overall current drawn must be less than the overall
rated current.
The phase arrangement A, B, C, D (or U, V, W, N) should be from left-
to-right or clockwise.
If you are attempting to start three non-synchronous motors, always
start with the heaviest duty motor first and then progress to the lighter
duty units.
Note: If overloading the circuit trips the circuit breaker, reduce the electrical load
on the circuit and then wait a few minutes before resuming operation.
6.2 DC application
1. The DC terminals are only for charging the 12V battery included with your
generator.
2. Set the “air” switch in the “OFF” position while charging the battery. On the
12V output terminals, a charge switch can be installed so that the unit can
be turned on and off as desired.
3. If your generator has an automatic battery with separate leads, make certain
that you disconnect the negative lead while you are charging the battery.
11
Caution
Identify and connect positive-to-positive and negative-to-negative poles from,
the battery to the engine. Crossing the wires will destroy both the battery
and the electrical components of your generator.
If you attempt to use a larger battery than recommended you will create
excessive current that will blow the fuse in the generator.
Do not attempt to operate the generator while it is still connected to the
battery.
Do not use a 12V battery and AC current at the same time.
Caution
All lead batteries emit explosive gas when being charged. Keep sparks,
flames and cigarettes away from the battery while charging. To prevent
sparks, always connect the booster cables to the battery first and then to the
generator. When the battery is charged, disconnect the cables from the
generator first.
Charge the battery in a well ventilated place.
Unless the battery is sealed, remove the caps from each cell before
charging.
Stop charging if the battery feels extremely hot. If the temperature exceeds
45C or 113F then the battery is too hot.
12
6.3 All electrical appliances, particularly motor driven equipment,
have extremely highly levels of current draw during their start-up
period. The table below provides a quick reference regarding
connecting different types of devices to the generator.
13
7. Stopping Your Generator
Step I: Disconnect all electrical plugs from the generator outlets before turning
off the generator!
Step II: Turn off the “AIR” switch on the generator.
Step III: Set the speed level in the “run” position, operating the generator for
about three minutes with nothing plugged in. Note: Do Not stop the generator
without this step, as the operating temperature of the engine will increase thereby
damaging the unit.
Step IV: Depress the “stop” lever
Step V: If the unit has an electric starter, turn the key to the “off” position.
1. Move the fuel lever to the “S” position.
Step VI: Retract the recoil starter handle until you feel resistance. (At this point
both the intake and exhaust valves are closed). Leave the handle in the position
as it prevents damp air from entering the engine and thereby prevents rust from
forming.
Warning:
Should the engine continue to operate when the speed lever is placed in
the “Stop” position, either turn the fuel valve to the “Close” position or
loosen the nut of the high pressure fuel pipe on the pump side of the
engine. If you do this, remember to tighten it again before attempting to
start the engine.
Do not attempt to stop the engine with the decompression lever.
Always make certain that all electrical plugs are removed from the
generator outlets before turning off your generator.
14
8. Periodic Maintenance and Testing
Periodic inspections and service are very important for maintaining your
generator’s engine in proper working order. The following chart indicates your
inspection and service frequency. Please keep this chart handy and refer to it as
needed.
Warning:
Turn off the engine before performing any service. If the engine must be in
operation, only do so in a well ventilated area as the exhaust contains
carbon monoxide which can be fatal.
After the generator has been operated, remove all dirt and sediments from
the outside cover to prevent corrosion.
Note:” ” indicates that special tools are required, please contact with agent.
15
8.1 Replacing the Engine Oil
1. Operate the engine for two to three minutes without allowing the engine
to get hot.
2. Turn off the engine
3. While the engine is still swarm,
remove the oil filter cap and the
drain plug located on the bottom of
the cylinder block, allowing the old
oil to drain. Insert the drain plug,
refill with recommended oil and
place the oil filter cap back on the
engine. Remember to recycle your
oil as it is a major cause of soil pollution.
The fuel oil filter also requires periodic cleaning to insure maximum engine
performance.
Cleaning: Every six months or 500 hours
Replacement: Every year or 1000 hours
16
1. Drain all fuel from the fuel tank.
8.6 Checking the injection nozzle and fuel injection pump requires
an authorize All-Power Service Center where they will:
1. Adjust the clearance for the intake/exhaust valves.
2. Grind the intake and exhaust valves
3. Replace the piston ring
Warning: Do not perform the injection nozzle test near an open flame as the fuel
may ignite. Do not expose bare skin to the fuel as it may cause injury. Always
keep away from the nozzle.
17
8.7 Checking refilling and charging the battery
Warning:
Batteries contain sulfuric acid which can burn your eyes and skin. Whenever
working with a battery, protect your eyes and skin from exposure to the acid.
In case of contact with any acid immediately thoroughly flush the affected
area with clean cold water and seek prompt medical attention.
8.8 Inspecting the carbon brush and slip ring. Periodically, check the
generators carbon brush and slip ring and readjust if there is a spark.
18
9. Long-Term Storage
If your plan on storing your generator for
periods of time exceeding one month,
please follow these guidelines:
3. While the engine is still warm, drain the crankcase oil by opening the oil
drain plug.
4. When all oil has drained, replace the plug and refill the oil reservoir with
clean oil.
5. Remove the screw plug on the cylinder head and refill of an ounce of
oil (22 CC) and replace the screw plug.
6. It is now necessary to turn the engine over without starting it.
a) Recoil Start: Push the decompression level down to the non-
compression position and hold it while pulling the recoil starter three
times.
b) Electric Start: Turn the engine for 2-3 seconds with the
decompression lever set in the non-compression mode and the key in
the “start” position.
7. Now pull the decompression lever up and pull the recoil starter slowly until
you begin to feel resistance. In this position both the intake and exhaust
valves are closed which prevents rust from forming inside the engine.
8. Wipe off any oil or dirt from the engine and store your generator in a dry
place.
19
10. Troubleshooting & Solutions
Fault Cause Remedy
Fuel oil is not sufficient Refill the fuel oil
Fuel cock is not at the Turn it to START position
STATE position
Fuel injection pump and Remove the nozzle and repair
nozzle do not delivery the it at test table
fuel or delivery in
sufficient fuel
The govemor lever is not Set the lever to START position
The diesel
at START position
engine can not
Low oil The specified oil level should
start
be between the upper level and
lower level
The nozzle is dirty Clean the nozzle
The speed and force to Start the engine according to
pull the recoil starter are the start procedures included in
not enough this book
The battery has no Charge it or replace it with a
electricity new one
Main switch not turned on Turn the main switch to ON
position
The carbon brush is worn Replace the carbon brush
The generating
The contact of the socket Adjust the socket
set can not
is not good
generate
The rated speed can no Adjust it according to the
be attached requirements
AVR is damaged Replace the AVR
20
GENERATOR DIAGRAM
Table 5-1.
Part Number
Number Part Description (CFA6500LN)
1 SILENCER COVER 1 CFA6500LN1
2 SILENCER BEND 1 CFA6500LN2
3 LEFT BOARD 1 CFA6500LN3
4 BACK DOOR 1 CFA6500LN4
5 FIXING SLEEVE FOR OBSERVING BORE 1 CFA6500LN5
21
GENERATOR PARTS LIST
20 CLIP 1 CFA6500LN20
21 FUEL INLET PIPE 1 1 CFA6500LN21
22 FUEL FILTER ASSEMBLY 1 CFA6500LN22
23 FUEL INLET PIPE 2 1 CFA6500LN23
24 FUEL LEAK-OFF PIPE CFA6500LN24
25 COVER OF U TYPE CHAMFER 1 CFA6500LN25
26 U TYPE CHAMFER 1 CFA6500LN26
27 SUPPORT OF U TYPE CHAMFER 1 CFA6500LN27
28 OUTPUT PIPE 1 CFA6500LN28
29 GASKET OF SILENCER 1 CFA6500LN29
30 UPPER SILENCER CFA6500LN30
31 LOW SILENCER 1 CFA6500LN31
32 BACK COVER OF ALTERNATOR 1 CFA6500LN32
33 BRACKET 1 CFA6500LN33
34 SHOCK ABSORPTION MAT 1 CFA6500LN34
35 TOW STRUCTURE OF 1 CFA6500LN35
ACCELERATOR
36 ELECTOMAGNET CFA6500LN36
37 BRACKET OF ELECTOMAGNET 1 CFA6500LN37
38 LONG COVER 1 CFA6500LN38
39 CHASSIS 1 CFA6500LN39
40 ROLLING WHEEL ON CHASSIS 1 CFA6500LN40
41 FLAT KEY 1 CFA6500LN41
42 PIN CFA6500LN42
43 MOTHERBOARD OF 1 CFA6500LN43
ACCUMULATOR
44 ACCUMULATOR 1 CFA6500LN44
45 BOLT 1 CFA6500LN45
46 PRESSINGPLAT E O F 1 CFA6500LN46
ACCUMULATOR
47 PULLING WIRE FOR THROTTLE 1 CFA6500LN47
48 PULLING WIRE FOR TURN-OFF CFA6500LN48
49 ALTERNATOR 1 CFA6500LN49
50 OUTPUT WIND LEADING SHAFT 1 CFA6500LN50
51 MANOSTAT 1 CFA6500LN51
52 GASKET OF OUTPUT BORE 1 CFA6500LN52
53 CF SERIES DISEL ENGINE 1 CFA6500LN53
54 PULLING ROLE FOR 1 CFA6500LN54
ACCELERATOR
55 INTAKE WIND LEADING SHAFT 1 CFA6500LN55
56 PRESSING PLAT E O F H I G H 1 CFA6500LN56
PRESSURE FUEL PIPE
57 SHOCK PREVENTING MAT 1 CFA6500LN57
58 SHOCK PREVENTING HOLDER 1 CFA6500LN58
A M6 16 BOLT,FLAT KEY 41 CFA6500LNA
B M6 8 BOLT 4 CFA6500LNB
C M4 8 BOLT 4 CFA6500LNC
D M6 12 BOLT 4 CFA6500LND
E M10 45 BOLT 4 CFA6500LNE
F M6 16 BOLT 4 CFA6500LNF
G M8 25 BOLT 5 CFA6500LNG
H M6 12 BOLT 17 CFA6500LNH
I M5 8 BOLT 12 CFA6500LNI
J M6 NUT 2 CFA6500LNJ
K M8 NUT FLAT SPRING WASHER 6 CFA6500LNK
L M10 NUT FLAT SPRING WASHER 12 CFA6500LNL
22
GENERATOR PARTS LIST
M M5 12 BOLT 2 CFA6500LNM
N M6 22 BOLT 2 CFA6500LNN
Figure 5-2.
Table 5-2.
23
GENERATOR PARTS LIST
Figure 5-3.
Table 5-3.
Part Number
Number Part Description Quantity
(CFA6500LN)
1 Front end cover 1 CFA6500LN86
2 Diode 2 CFA6500LN87
3 M4 x 8 Bolt 2 CFA6500LN88
4 Fan Blade 1 CFA6500LN89
5 Bearing 1 CFA6500LN90
6 Rotor Unit 1 CFA6500LN91
7 Center bolt 1 CFA6500LN92
8 Motor cover 1 CFA6500LN93
9 Stator 1 CFA6500LN94
10 Long bolt 4 CFA6500LN95
11 Capacitor 1 CFA6500LN96
12 Wiring Seat 1 CFA6500LN97
13 M5 x 15 Bolt 6 CFA6500LN98
14 Stator Unit 1 CFA6500LN99
15 Dust Cover 1 CFA6500LN100
24
LIMITED WARRANTY
All-Power America warrants to the original purchaser who uses the product in a
consumer application (personal, residential or household usage) that all
products covered under this Warranty are free from defects in material and
workmanship for one year from the date of purchase. All products covered by
this limited Warranty which are used in commercial applications (i.e. income
producing) are warranted to be free of defects in material and workmanship for
90 days from the date of original purchase. Products covered under this
Warranty include air compressors, air tools, service parts, pressure washers
and generators.
This warranty gives you specific legal rights, and you may also have other
rights which vary from state to state.
25
LIMITED WARRANTY
THIS WARRANTY DOES NOT COVER:
Merchandise sold as reconditioned, used as rental equipment, or floor or
display models.
Merchandise that has become damaged or inoperative because of ordinary
wear, misuse, cold, heat, rain, excessive humidity, freeze damage, use of
improper chemicals, negligence, accident, failure to operate the product
in accordance with the instructions provided in the Owner’s Manual(s)
supplied with the product, improper maintenance, the use of accessories
or attachments not recommended by All-Power America, or unauthorized repair
or alterations.
Repair and transportation costs of merchandise determined not to be defective.
Costs associated with assembly, required oil, adjustments or other installation
and start-up costs.
Expendable parts or accessories supplied with the product which are
expected to become inoperative or unusable after a reasonable period of
use.
Merchandise sold by All-Power America which has been manufactured by
and identified as the product of another company, such as gasoline
engines. The product manufacturer's Warranty, if any, will apply.
ANY INCIDENTAL, INDIRECT OR CONSEQUENTIAL LOSS, DAMAGE, OR
EXPENSE THAT MAY RESULT FROM ANY DEFECTS, FAILURE OR
MALFUNCTION OF THE PRODUCT IS NOT COVERED BY THIS
WARRANTY. Some states do not allow the exclusion, so it may not apply to
you. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO ONE YEAR
FROM THE DATE OF ORIGINAL PURCHASE. Some states do not allow
limitations on how long an implied warranty lasts, so the above limitations may
not apply
Distributed by:
ALL-POWER AMERICA
©2005 ALL-POWER AMERICA
16273 E. Gale Ave
City Of Industry, California 91745
www.allpoweramerica.com
26